Robustness analysis in the modeFRONTIER environment applied to the development of hydraulic pump components using CAE tools

In modern hydraulic pumps, internal components are optimized through traditional calculations and CAE simulations coupled in multi-objective optimization workflows: at Casappa, these processes have been structured for years using modeFRONTIER software and continue to be refined and further evolved. This work aims to move beyond the deterministic approach, where a design is simulated only at its nominal value, by integrating robustness analysis (and/or robust optimization) into the optimization process. This involves evaluating a 'cloud of samples' within the appropriate neighborhood of the nominal values for the relevant manufacturing tolerances. The approach was applied to three real-world cases of increasing complexity: the results demonstrate that solutions can exist with performance trade-offs similar to those traditionally chosen, while being more robust, offering direct benefits in terms of repeatability and reliability of the finished product during industrialization and mass production.